JP2012059643A - Optical unit - Google Patents

Abstract

PROBLEM TO BE SOLVED: To raise rigidity of an optical unit used for a vehicular lamp fitting.SOLUTION: The optical unit 100 used for a vehicular lamp fitting includes a heat sink 130 for radiating heat of a light source module 200, a base section 150 having a reflector-mounting section 152, a lens-mounting section 154, and a combining section 156 of the reflector-mounting section 152 and the lens-mounting section 154, wherein light of the light source module 200 is reflected with a reflector 110 mounted on the reflector-mounting section 152 and is incident to a projection lens 102 mounted on the lens-mounting section 154, and a coupling mechanism 170 of the heat sink 130 and the base section 150. The heat sink 130 has an extension section 134 extended further toward front of an optical axis direction of the optical unit 100 rather than a front end of the reflector-mounting section 152 past a lower part of the reflector-mounting section 152, and the coupling mechanism 170 couples the coupling section 156 and the extension section 134.

Description

  The present invention relates to an optical unit, and more particularly to an optical unit used for a vehicular lamp.

  2. Description of the Related Art Conventionally, an optical unit for a vehicular lamp is known in which light from a light source such as a semiconductor light emitting element is reflected by a reflector and irradiated to the front of the vehicle through a projection lens. This optical unit has a structure in which a base portion to which a projection lens and a reflector are attached is connected to a heat sink having a mounting portion for a semiconductor light emitting element.

  In this optical unit, as shown in FIG. 6 of Patent Document 1, for example, a shade corresponding to the base portion is attached to the heat sink by a fastening screw extending through the heat sink from the back side of the heat sink. Specifically, the shade includes a flat portion arranged substantially horizontally and a curved portion that is curved downward so as not to block the incidence of the light source light on the projection lens in front of the flat portion. And the internal thread part was provided in the back side of the curved part, and the shade was attached to the heat sink by the fastening screw extended from the back side of a heat sink screwing in this internal thread part.

JP 2007-35547 A

  As described above, in the configuration in which the base portion is attached to the heat sink by the fastening screw extending from the back side of the heat sink, the rear portion of the base portion is connected to the heat sink. On the other hand, the base portion has a relatively heavy projection lens attached to the front end portion, so that the center of gravity is closer to the front. Therefore, the position of the connecting part of the base part and the heat sink is separated from the position of the center of gravity of the base part. For this reason, there is room for improvement in the conventional configuration in order to increase the rigidity of the optical unit against vibration and impact transmitted to the optical unit when the vehicle is traveling.

  This invention is made | formed in view of such a condition, The objective is to provide the technique which can improve the rigidity of the optical unit used for a vehicle lamp.

  In order to solve the above-described problems, an optical unit according to an aspect of the present invention is an optical unit used in a vehicle lamp, and includes a heat sink for radiating light from a light source, a reflector mounting portion, a lens mounting portion, and a reflector mounting. A base portion configured to have a coupling portion of the lens mounting portion and the lens mounting portion, the light of the light source reflected by a reflector attached to the reflector mounting portion and incident on a projection lens attached to the lens mounting portion, and a heat sink and a base portion The heat sink includes an extension that extends below the reflector mounting portion and extends forward in the optical axis direction of the optical unit from the front end of the reflector mounting portion. The coupling mechanism includes a coupling portion and an extension portion. Are connected.

  According to this aspect, the rigidity of the optical unit used in the vehicular lamp can be increased.

  In the above aspect, the coupling mechanism may be provided at a position overlapping the projection lens attached to the lens attachment portion when the optical unit is viewed from the front. According to this, it is possible to reduce the size of the optical unit.

  In the above aspect, the coupling mechanism includes a screw having a head, a screw through hole provided in the coupling portion, and a screw receiving portion provided in the extension portion, and the screw is inserted into the screw through hole to receive the screw receiver. The coupling portion may be sandwiched between the head portion and the extension portion. According to this, since it becomes possible to provide a radiation fin also in the back surface side part of the screw receiving part in an extension part, the heat dissipation of an optical unit can be improved.

  In the above aspect, the coupling portion has a plurality of convex portions that are pressed against the head around the screw hole, and at least one of the base portion and the heat sink has a plurality of abutting portions that are in contact with the other. The convex portion may extend substantially perpendicularly to a straight line at least a part of which passes through the center of the screw hole and the center of the butting portion. According to this, since the transmission amount of the force by which the screw head crushes the convex portion to the abutting portion can be increased, the positioning of the heat sink and the base portion in the distance direction can be performed with high accuracy.

  In the above aspect, the abutting portion may be disposed on the periphery of the screw-through hole, and a part of the convex portion may extend radially with respect to the center of the screw-through hole. According to this, it can prevent that the force which the head part of a screw crushes a convex part is transmitted excessively to the abutting part arrange | positioned at the periphery of a screw through hole.

  ADVANTAGE OF THE INVENTION According to this invention, the rigidity of the optical unit used for a vehicle lamp can be improved.

1 is a schematic partial cross-sectional view illustrating an internal structure of a vehicle headlamp device as a vehicle lamp including an optical unit according to Embodiment 1. FIG. It is the schematic perspective view which looked at the optical unit which concerns on Embodiment 1 from diagonally upward. 3A is a schematic perspective view of the reflector as viewed from obliquely above, FIG. 3B is a schematic perspective view of the reflector as viewed from obliquely below, and FIG. It is the schematic perspective view seen from diagonally downward. It is the schematic perspective view which looked at the heat sink from diagonally upward. FIG. 5A is a schematic perspective view of the base portion as viewed obliquely from above, and FIG. 5B is a schematic perspective view of the base portion as viewed obliquely from below. 6A is a schematic plan view of the vicinity of the coupling portion of the base portion, and FIG. 6B is a schematic cross-sectional view along the line AA in FIG. 6A. It is a disassembled perspective view of an optical unit. FIG. 8A is a schematic perspective view of the base portion assembled with the reflector and the projection lens as viewed from obliquely above, and FIG. 8B shows the base portion assembled with the reflector and the projection lens from obliquely below. FIG. FIG. 9A to FIG. 9C are schematic views for explaining a method of assembling the reflector to the base portion. It is the schematic perspective view which looked at the state where the base part with which the reflector and the projection lens were assembled | attached to the heat sink was seen from diagonally upward. It is a schematic sectional drawing along the plane containing the central axis of the screw in the state where the base part was assembled to the heat sink. FIGS. 12A to 12F are schematic views for explaining a method of assembling the base portion to the heat sink. 2 is a schematic front view of the optical unit according to Embodiment 1. FIG. It is a schematic plan view of the vicinity of the coupling portion of the base portion in the optical unit according to the modification.

  The present invention will be described below based on preferred embodiments with reference to the drawings. The same or equivalent components, members, and processes shown in the drawings are denoted by the same reference numerals, and repeated descriptions are omitted as appropriate. The embodiments do not limit the invention but are exemplifications, and all features and combinations thereof described in the embodiments are not necessarily essential to the invention.

(Embodiment 1)
FIG. 1 is a schematic partial cross-sectional view illustrating an internal structure of a vehicle headlamp device as a vehicle lamp including the optical unit according to the first embodiment. FIG. 2 is a schematic perspective view of the optical unit according to Embodiment 1 as viewed obliquely from above. The vehicle headlamp device has a pair of left and right headlamp units formed symmetrically. When the vehicle headlamp device is mounted on the vehicle, one of the headlamp units is connected to the left side of the vehicle. It is provided in the front part, and the other is provided in the right front part of the vehicle. FIG. 1 shows a configuration of a left or right headlamp unit as a vehicle headlamp device.

  As shown in FIG. 1, a vehicle headlamp device 10 according to the present embodiment includes a lamp body 12 having an opening on the front side of the vehicle, and a translucent cover attached so as to cover the opening of the lamp body 12. 14. The translucent cover 14 is made of translucent resin, glass, or the like. An optical unit 100 is accommodated in a lamp chamber 13 formed by the lamp body 12 and the translucent cover 14.

  As shown in FIGS. 1 and 2, the optical unit 100 is a so-called projector-type optical unit used for a vehicle lamp, and includes a reflector 110, a heat sink 130, and a base portion 150. Further, the optical unit 100 of the present embodiment is an optical unit capable of forming a low beam light distribution pattern. The optical unit 100 is arranged so that its optical axis extends in the vehicle front-rear direction and is connected to the lamp body 12.

  The reflector 110 has a reflection surface 110a for reflecting light from the light source module 200 (light source). The heat sink 130 includes a light source mounting part 132 on which the light source module 200 is mounted, an extension part 134 that extends forward from the front surface of the light source mounting part 132 in the optical axis direction, and a heat radiation fin 135 provided on the extension part 134. In addition, the heat sink 130 includes a back surface portion 136 that extends upward from the upper surface of the back surface of the light source mounting portion 132, and heat radiation fins 137 provided on the back surface portion 136. The base unit 150 includes a reflector mounting part 152 having a reflector mounting surface 152a, a lens mounting part 154 to which the projection lens 102 is mounted, and a coupling part 156 of the reflector mounting part 152 and the lens mounting part 154.

  The heat sink 130 functions as a support member for supporting the reflector 110 and the base portion 150, and the base portion 150 to which the reflector 110 is attached is coupled to the heat sink 130 by the coupling mechanism 170. The heat sink 130 has screw holes 138 in the lower rear portion of the light source mounting portion 132 and the rear surface of the rear portion 136, and the aiming screw 16 extending through the lamp body 12 and the leveling shaft 18 extends forward. Screwed into the hole 138. In this way, the heat sink 130 is attached to the lamp body 12, whereby the optical unit 100 is attached to the lamp body 12.

  The leveling shaft 18 is connected to the leveling actuator 20. The vehicle headlamp device 10 is configured such that the optical axis of the optical unit 100 can be adjusted in the horizontal and vertical directions by the aiming screw 16, the leveling shaft 18, and the leveling actuator 20.

  Subsequently, referring to FIG. 3A to FIG. 3C, FIG. 4, FIG. 5A, FIG. 5B, FIG. 6A, and FIG. The structure of each part will be described in detail. 3A is a schematic perspective view of the reflector as viewed from obliquely above, FIG. 3B is a schematic perspective view of the reflector as viewed from obliquely below, and FIG. It is the schematic perspective view seen from diagonally downward. FIG. 4 is a schematic perspective view of the heat sink as viewed obliquely from above. FIG. 5A is a schematic perspective view of the base portion as viewed obliquely from above, and FIG. 5B is a schematic perspective view of the base portion as viewed obliquely from below. 6A is a schematic plan view of the vicinity of the coupling portion of the base portion, and FIG. 6B is a schematic cross-sectional view along the line AA in FIG. 6A.

  As shown in FIGS. 3A and 3B, the reflector 110 is a reflecting member in which a reflecting surface 110a made of, for example, a part of a spheroidal surface is formed on the inner side. In the reflector 110, the first focal point of the reflecting surface 110a is located in the vicinity of the light source module 200 (see FIG. 1), and the second focal point of the reflecting surface 110a is located in the vicinity of the rear focal point of the projection lens 102 (see FIG. 1). Thus, it is arranged on the vehicle rear side with respect to the projection lens 102.

  The reflector 110 has a facing surface 112 that faces the reflector mounting surface 152a in a state of being attached to the reflector mounting portion 152 of the base portion 150. On the opposing surface 112, a fixing pin 114 used for fixing the reflector 110 and the base portion 150, a positioning pin 116 for positioning the reflector 110 and the base portion 150 in the horizontal direction, and a distance between the reflector 110 and the base portion 150. A convex abutting portion 118 for positioning in the direction (vertical direction) is provided. In the present embodiment, the facing surface 112 extends in a substantially elliptical arc shape and is arranged to be line symmetric with respect to the optical axis. One fixing pin 114 and one positioning pin 116 are provided on each of the left and right sides of the optical axis. Two abutting portions 118 are provided on both the left and right sides of the optical axis, and one abutting portion 118 on each side is disposed on the vehicle front side with respect to the fixing pin 114 and the positioning pin 116, and the other is disposed on the other side. The fixed pin 114 and the positioning pin 116 are disposed on the vehicle rear side.

  As shown in FIG. 3C, the fixing pin 114 has a large-diameter portion 114 a having a larger diameter than a pin hole 158 described later provided in the base portion 150. The large diameter portion 114 a is provided at the base end portion of the fixing pin 114, that is, a position in contact with the facing surface 112. The large diameter portion 114a has a parallel surface 114b. The parallel surface 114b is a surface parallel to the reflector mounting surface 152a in a state where the reflector 110 is attached to the reflector attaching portion 152 of the base portion 150. That is, the fixing pin 114 has a step on its side surface that has a larger diameter on the base end side than the tip end side, and the base end side becomes a large diameter portion 114a from this step, and the side surface of the large diameter portion 114a has a large diameter. A surface connecting the side surface of the fixing pin 114 on the tip side with respect to the portion 114a is a parallel surface 114b.

  The height of the fixing pin 114 is larger than the thickness of the portion of the base portion 150 where the pin hole 158 is provided, in other words, the length of the pin hole 158. In addition, the height of the large diameter portion 114a is such a height that a gap is formed between the parallel surface 114b and the reflector mounting surface 152a in a state where the reflector 110 is attached to the reflector attachment portion 152 of the base portion 150. ing.

  The heat sink 130 is a member for radiating heat from the light source module 200. As shown in FIG. 4, the heat sink 130 has a light source mounting part 132 for mounting the light source module 200. The light source mounting part 132 has a substantially rectangular parallelepiped shape (see FIGS. 1 and 2), and has a light source mounting surface 132a on which the light source module 200 is mounted. On the side surface of the light source mounting portion 132 facing the vehicle front side, a flat plate-like extension portion 134 that extends forward in the optical axis direction to the vicinity of the projection lens 102 is provided. The extension part 134 is disposed so that the main surface thereof extends substantially horizontally, and a plurality of heat radiation fins 135 are provided on the main surface facing upward so as to be arranged in the left-right direction of the vehicle. The heat radiating fins 135 extend in the vehicle front-rear direction, and their rear surfaces are in contact with the side surfaces of the light source mounting portion 132 facing the vehicle front side. Further, the height of the upper surface of the heat dissipating fin 135 is substantially the same as the upper surface of the light source mounting portion 132 on the rear side of the vehicle, and the front side of the vehicle is forward of the vehicle so as not to block the light that is reflected by the reflector 110 and directed toward the projection lens 102 It is so low.

  The extension portion 134 is provided with a screw receiving portion 176 that constitutes a connection mechanism 170 described later, on the outer side in the vehicle left-right direction with respect to the radiation fins 135. One screw receiving portion 176 is provided on each of the left and right sides. The extension portion 134 is provided with positioning pins 140 for positioning the heat sink 130 and the base portion 150 in the horizontal direction on the vehicle rear side of the screw receiving portions 176 at both ends in the left-right direction of the vehicle. One positioning pin 140 is provided on each of the left and right sides.

  A flat plate-like back surface portion 136 extending in the vehicle vertical direction is provided on the side surface of the light source mounting portion 132 facing the vehicle rear side. The back surface portion 136 is disposed such that its main surface faces in the vehicle front-rear direction, and a plurality of heat radiation fins 137 are arranged in the vehicle left-right direction on the main surface facing the vehicle rear side. Further, a screw hole 138 into which the aiming screw 16 (see FIG. 1) is screwed is provided on the main surface of the rear portion 136 facing the vehicle rear side, and the leveling shaft 18 is formed on the side surface of the light source mounting portion 132 facing the vehicle rear side. A screw hole 138 into which (see FIG. 1) is screwed is provided. The heat sink 130 is made of, for example, aluminum die cast, and the light source mounting part 132, the extension part 134, the heat radiation fin 135, the back surface part 136, the heat radiation fin 137, the screw hole 138, and the screw receiving part 176 are integrally formed.

  As shown in FIG. 1, the light source module 200 includes, for example, a semiconductor light emitting element 202 such as a light emitting diode (LED), and a substrate 204 that supports the semiconductor light emitting element 202. The substrate 204 is a thermally conductive insulating substrate made of ceramic or the like. An electrode (not shown) that transmits electric power to the semiconductor light emitting element 202 is formed on the substrate 204. The light source module 200 is mounted on the light source mounting portion 132 with the light emitting surface of the semiconductor light emitting element 202 facing upward in the vehicle and the irradiation axis of the semiconductor light emitting element 202 extending substantially in the vehicle vertical direction.

  The base unit 150 is a member for supporting the reflector 110 and the projection lens 102 (see FIGS. 1 and 2). As shown in FIGS. 5A and 5B, the base portion 150 includes a reflector mounting portion 152 having a reflector mounting surface 152a. The reflector mounting portion 152 has a flat plate shape, and is disposed such that its main surface faces the vehicle vertical direction, and the main surface facing the vehicle upper side is a reflector mounting surface 152a. Further, the reflector mounting portion 152 forms a shade whose front end portion 152b forms a cut-off line of a low beam light distribution pattern (light distribution pattern). That is, the shape of the ridgeline formed by the side surface of the reflector mounting portion 152 on the vehicle front side and the reflector mounting surface 152a corresponds to the cut-off line shape of the low beam light distribution pattern. The front end portion 152b is disposed in the vicinity of the second focal point of the reflecting surface 110a and the rear focal point of the projection lens 102.

  A coupling portion 156 is connected to both left and right end portions of the reflector mounting portion 152. The coupling portion 156 corresponds to a pair of arm portions that extend from the reflector mounting portion 152 toward the front of the vehicle and support the lens mounting portion 154 at the tip thereof. A lens mounting portion 154 is connected to the end portion of the coupling portion 156 on the vehicle front side, whereby the reflector mounting portion 152 and the lens mounting portion 154 are coupled. Further, the coupling portion 156 is provided with a screw hole 174 that constitutes a coupling mechanism 170 described later.

  The lens mounting portion 154 is a substantially cylindrical member, and a coupling portion 156 is connected to a surface facing the vehicle rear side, and the projection lens 102 is fixed to a surface facing the vehicle front side. A plurality of fixing pins 154 a for fixing the projection lens 102 are provided on the surface of the lens mounting portion 154 facing the vehicle front side.

  The base unit 150 is configured so that the light of the light source module 200 is reflected by the reflector 110 attached to the reflector attaching part 152 and is incident on the projection lens 102 attached to the lens attaching part 154 while being attached to the heat sink 130. . The base portion 150 is made of, for example, resin, and the reflector mounting portion 152, the lens mounting portion 154, and the coupling portion 156 are integrally formed.

  A pin hole 158 into which the fixing pin 114 is inserted is provided at a position corresponding to the fixing pin 114 provided on the reflector 110 in the base portion 150. In addition, a positioning hole 160 into which the positioning pin 116 is inserted is provided at a position corresponding to the positioning pin 116 provided in the reflector 110 in the base portion 150. In the present embodiment, one pin hole 158 and one positioning hole 160 are provided at both ends of the reflector mounting portion 152 in the vehicle left-right direction. Further, the reflector mounting surface 152 a has an abutment receiving portion 162 with which the abutment portion 118 abuts at a position corresponding to the abutment portion 118 of the reflector 110.

  The base portion 150 has a plurality of abutting portions 164 for positioning in the distance direction (vertical direction) of the two by contacting the heat sink 130 when attached to the heat sink 130. The base portion 150 is mounted on the heat sink 130 such that the main surface of the reflector mounting portion 152 on the vehicle lower side faces the heat sink 130 side. Therefore, in the present embodiment, a convex abutting portion 164a is provided on the main surface of the reflector mounting portion 152 on the vehicle lower side, and a convex abutting portion 164b is provided on the surface of the coupling portion 156 facing the vehicle lower side. It has been. Specifically, one abutment portion 164a is disposed at each end portion in the vehicle width direction on the main surface of the reflector mounting portion 152 on the vehicle lower side. The abutting portion 164b is disposed on the periphery of the screw through hole 174 provided in the coupling portion 156. The abutting portion 164 is preferably disposed on a line that passes through the screw hole 174 and extends in the vehicle front-rear direction. Further, the base portion 150 has a pin hole 166 into which the positioning pin 140 is inserted at a position corresponding to the positioning pin 140 provided in the heat sink 130.

  As shown in FIGS. 6A and 6B, the coupling portion 156 of the base portion 150 has a plurality of convex portions 168 around the screw through hole 174. The plurality of convex portions 168 come into contact with the heads of the screws 172 when screws 172 constituting the coupling mechanism 170 described later are screwed into the screw receiving portions 176 of the heat sink 130 inserted through the screw through holes 174. It is configured to be crushed. In the present embodiment, each of the plurality of convex portions 168 has a shape in which one side surface of the triangular prism is in contact with the surface of the coupling portion 156 and the top portion facing the one side surface protrudes upward, and the screw 172 is the screw receiving portion 176. When screwed together, the top portion protruding upward is crushed.

  Further, the plurality of convex portions 168 extend substantially perpendicularly to a straight line L passing through the center M of the screw-through hole 174 and the center N of the abutting portion 164a disposed away from the screw-through hole 174. . That is, each of the plurality of convex portions 168 is arranged such that a top portion protruding upward and a skirt portion in contact with the surface of the coupling portion 156 extend substantially perpendicular to the straight line L. The “substantially perpendicular” means that not only the case where the convex portion 168 extends perpendicular to the straight line L but also the amount of transmission of the force that presses the convex portion 168 to the abutting portion 164a can be increased. All of the shapes capable of producing the effect of being included are included.

  As shown in FIGS. 1 and 2, the projection lens 102 is a plano-convex aspheric lens having a convex front surface and a flat rear surface. The projection lens 102 is fixed to the lens mounting portion 154 and provided on the optical axis of the optical unit 100. In the vicinity of the rear focus of the projection lens 102, the second focal point of the reflecting surface 110a and the front end portion 152b of the reflector mounting portion 152 are provided. positioned. The projection lens 102 functions as an optical member that condenses the light emitted from the light source module 200 and projects it in front of the lamp.

  Next, refer to FIGS. 7, 8A, 8B, 9A to 9C, 10, 11, and 12A to 12F. The assembly of the optical unit 100 will be described.

  FIG. 7 is an exploded perspective view of the optical unit. FIG. 8A is a schematic perspective view of the base portion assembled with the reflector and the projection lens as viewed from obliquely above, and FIG. 8B shows the base portion assembled with the reflector and the projection lens from obliquely below. FIG. FIG. 9A to FIG. 9C are schematic views for explaining a method of assembling the reflector to the base portion. 9A is a schematic side view of the vicinity of the fixing pin in a state where the reflector is assembled to the base portion, and FIG. 9B includes the central axis of the fixing pin in the state shown in FIG. 9A. FIG. 9C is a schematic cross-sectional view along a plane, and FIG. 9C is a schematic cross-sectional view showing a state where the tip of the fixing pin is welded to the base portion. FIG. 10 is a schematic perspective view of a state in which a base portion on which a reflector and a projection lens are assembled is assembled to a heat sink, as viewed obliquely from above. In FIG. 10, the projection lens 102 is not shown. FIG. 11 is a schematic cross-sectional view along a plane including the central axis of the screw in a state where the base portion is assembled to the heat sink. FIGS. 12A to 12F are schematic views for explaining a method of assembling the base portion to the heat sink. 12 (A) to 12 (C) show a state before screwing, and FIGS. 12 (D) to 12 (F) show a state after screwing. 12 (A) and 12 (D) are schematic plan views of the vicinity of the coupling portion in each state, and FIGS. 12 (B) and 12 (E) are screw through holes in each state. It is a schematic sectional drawing along the plane containing a central axis, and Drawing 12 (C) and Drawing 12 (F) are the schematic perspective views which looked at the joint part neighborhood in each state from the slanting upper part. In addition, illustration of the screw is abbreviate | omitted in FIG.12 (D)-FIG.12 (F).

  As shown in FIGS. 7, 8 </ b> A, and 8 </ b> B, the projection lens 102 is disposed on the vehicle front side of the base unit 150 so that the plane faces the base unit 150 side. Then, the fixing pin 154a of the lens mounting portion 154 and the concave portion provided on the periphery of the projection lens 102 are aligned, and the projection lens 102 is pressed against the lens mounting portion 154. Thereby, the projection lens 102 is fixed to the lens mounting portion 154. In addition, the reflector 110 is arranged above the reflector placement surface 152a such that the facing surface 112 (see FIG. 3B) faces the reflector placement surface 152a. Then, the fixing pin 114 of the reflector 110 and the pin hole 158 of the base portion 150 are aligned, the positioning pin 116 of the reflector 110 and the positioning hole 160 of the base portion 150 are aligned, and the reflector 110 is placed on the reflector mounting surface. 152a.

  As shown in FIGS. 9A and 9B, when the reflector 110 is placed on the reflector placement surface 152a, the fixing pin 114 is inserted into the pin hole 158. The fixed pin 114 inserted into the pin hole 158 protrudes from the pin hole 158 toward the back side of the reflector mounting surface 152a. Further, the positioning pins 116 are inserted into the positioning holes 160 (see FIG. 7), so that the reflector 110 and the base portion 150 are positioned in the vehicle front-rear left-right direction, that is, in the horizontal direction. Further, the abutting portion 118 provided on the opposing surface 112 of the reflector 110 contacts the abutting receiving portion 162 of the reflector mounting surface 152a, so that the reflector 110 and the base portion 150 are in the vehicle vertical direction, that is, the vertical direction (distance direction). ) Is positioned.

  As shown in FIG. 9C, the distal end portion of the fixing pin 114 protruding from the pin hole 158 is deformed by, for example, heat caulking, whereby the pin head having a diameter larger than the opening diameter of the pin hole 158 114c is formed. The pin head 114c prevents the reflector 110 from falling off the base portion 150. In the present embodiment, the base unit 150 is placed on the pedestal of the heat caulking device, and the reflector 110 is pressed against the base unit 150 with a predetermined pressure at a predetermined temperature. As a result, the tip end portion of the fixing pin 114 protruding from the pin hole 158 is melted and deformed to form the pin head portion 114c. In addition, the formed pin head 114 c is welded to the base portion 150.

  Thus, in this embodiment, the fixing pin 114 is inserted into the pin hole 158 and the reflector 110 is fixed to the base portion 150. Therefore, it is possible to prevent the reflector from being deformed in the conventional structure in which the reflector is attached to the base portion by lance engagement. As a result, it is possible to improve the formation accuracy of the light distribution pattern. Further, in this embodiment, since the fixing pin 114 is erected on the opposing surface 112, the outer dimensions of the reflector 110 are larger than those of the conventional structure in which the hook of the lance engagement mechanism is provided on the outer surface of the reflector 110. Can be small. Thereby, the external dimension of the optical unit 100 can be reduced and the degree of design freedom can be improved.

  In addition, since the tip end portion of the fixing pin 114 is heat caulked and welded to the base portion 150, the reflector 110 and the base portion 150 can be firmly fixed, and the reflector 110 is prevented from falling off the base portion 150. It can be surely prevented. The method of fixing the reflector 110 to the base portion 150 is not limited to the method of welding the distal end portion of the fixing pin 114 to the base portion 150. For example, the diameter of the fixing pin 114 is made larger than the opening diameter of the pin hole 158. The fixing pin 114 may be press-fitted into the pin hole 158, or a combination thereof may be used. In addition, “the fixing pin 114 is inserted into the pin hole 158 and the reflector 110 is fixed to the base portion 150” is deformed after the fixing pin 114 is inserted into the pin hole 158 as in the case of heat caulking. Thus, the case where the reflector 110 and the base portion 150 are fixed and the case where the fixing pin 114 is inserted and fixed as in the case of press-fitting are included.

  When heat caulking is applied to the distal end portion of the fixing pin 114, the reflector 110 is pressed toward the base portion 150. Therefore, the reflector 110 is bent at the portion between the two abutting portions 118 with the abutting portion 118 on the vehicle front side of the fixing pin 114 and the abutting portion 118 on the vehicle rear side as a fulcrum. The reflective surface 110a may be deformed. On the other hand, as shown in FIG. 9B and FIG. 9C, the fixing pin 114 in the present embodiment is located at a position within the region between the facing surface 112 and the reflector mounting surface 152a. A large diameter portion 114 a having a diameter larger than that of the pin hole 158 is provided. Therefore, only the portion of the fixing pin 114 closer to the tip than the large diameter portion 114a can be inserted into the pin hole 158. Thereby, it is possible to prevent the fixing pin 114 from excessively entering the pin hole 158 and deforming the reflecting surface 110a. That is, since the amount of the fixed pin 114 entering the pin hole 158 can be adjusted, the deflection of the reflector 110 due to the pressing during heat caulking can be reduced, and the deformation of the reflecting surface 110a can be avoided.

  The large diameter portion 114a has a parallel surface 114b parallel to the reflector mounting surface 152a. Therefore, when the fixed pin 114 enters the pin hole 158 and the large-diameter portion 114a reaches the reflector mounting surface 152a, the parallel surface 114b and the reflector mounting surface 152a come into surface contact with each other, and more than that of the fixed pin 114. The entry of is suppressed. Therefore, it is possible to more reliably prevent the fixing pin 114 from entering the pin hole 158. In addition, in a state after the heat caulking process of the fixing pin 114, that is, in a state where the pressure on the reflector 110 and the base portion 150 is released, between the parallel surface 114b and the reflector mounting surface 152a, A void H is formed. As described above, since the gap H is provided between the parallel surface 114b and the reflector mounting surface 152a, high-precision surface height management of the parallel surface 114b can be omitted, so that the manufacturing process of the base portion 150 is complicated. Can be prevented.

  Subsequently, as illustrated in FIGS. 7 and 10, the light source module 200 is mounted on the light source mounting portion 132 of the heat sink 130, and the light source module 200 is fixed to the heat sink 130. In addition, a base portion 150 to which the projection lens 102 and the reflector 110 are attached is disposed above the light source mounting portion 132 of the heat sink 130. Then, the pin hole 166 of the base portion 150 and the positioning pin 140 of the heat sink 130 are aligned, and the screw through hole 174 provided in the coupling portion 156 of the base portion 150 and the screw receiver provided in the extension portion 134 of the heat sink 130. The base part 150 is placed on the heat sink 130 with the part 176 aligned. In a state where the base portion 150 is placed on the heat sink 130, the reflector mounting portion 152 is in contact with the upper surface on the vehicle front side of the light source module 200 of the light source mounting portion 132 and the upper surface of the radiating fin 135 on the vehicle rear side. Further, the positioning pins 140 are inserted into the pin holes 166, and the base portion 150 and the heat sink 130 are positioned in the horizontal direction. Further, the abutting portions 164a and 164b of the base portion 150 come into contact with the heat sink 130, and the base portion 150 and the heat sink 130 are positioned in the distance direction (see FIG. 11). Further, the tip of the screw receiving portion 176 is inserted into the screw through hole 174.

  Then, a screw 172 having a head 172 a is inserted into the screw hole 174 and screwed into the screw receiving portion 176. Here, as shown in FIG. 11, the coupling mechanism 170 that couples the heat sink 130 and the base portion 150 includes a screw 172 having a head portion 172 a, a screw through hole 174 provided in the coupling portion 156, and an extension portion 134. A screw receiving portion 176 provided on the screw 172, and the screw 172 is inserted into the screw through hole 174 and screwed into the screw receiving portion 176, whereby the coupling portion 156 is connected to the head portion 172a of the screw 172 and the extension portion 134. Will be sandwiched. In this way, the connecting mechanism 170 connects the coupling portion 156 and the extension portion 134, thereby connecting the base portion 150 and the heat sink 130.

  As shown in FIGS. 12A to 12C, the upper surface of the screw receiving portion 176 inserted into the screw through hole 174 is lower than the top of the convex portion 168 in a state before being fastened by the screw 172. It has become. Then, the screw 172 is inserted into the screw receiving portion 176 until the lower surface of the head portion 172a contacts the upper surface of the screw receiving portion 176 (see FIG. 11). As a result, the head 172a of the screw 172 presses the top of the convex portion 168 above the upper surface of the screw receiving portion 176, thereby pressing the coupling portion 156 toward the extension portion 134. Then, the abutting portion 164 of the coupling portion 156 is pressed against the heat sink 130 and the base portion 150 is fixed to the heat sink 130.

  At this time, as shown in FIGS. 12D to 12F, the top of the convex portion 168 located above the upper surface of the screw receiving portion 176 is crushed by the head portion 172a and plastically deformed. And the force which crushes this convex part 168 is transmitted to the abutting part 164, and the abutting part 164 can be reliably pressed against the heat sink 130. FIG. That is, the convex portion 168 functions as a crushing allowance for fixing the base portion 150 to the heat sink 130.

  As the abutting portion 164 moves away from the contact portion between the screw 172 and the convex portion 168, the force that crushes the convex portion 168 is less likely to be transmitted. Therefore, the force transmitted to the abutting portion 164a disposed away from the coupling mechanism 170 is smaller than that of the abutting portion 164b provided immediately below the region where the convex portion 168 exists. Therefore, in the present embodiment, the convex portion 168 is provided so as to extend substantially perpendicular to the straight line L passing through the center M of the screw through hole 174 and the center N of the butting portion 164a (see FIG. 6A). ). The force that presses or crushes the convex portion 168 is easily transmitted in the direction in which the skirt expands from the top of the convex portion 168. Therefore, a plurality of convex portions 168 are arranged so that the top and bottom portions of the convex portions 168 extend substantially perpendicular to the straight line L, and the transmission direction of the pressing force from each convex portion 168 is directed toward the abutting portion 164a. By aligning them, it is possible to increase the amount of transmission of the force that presses the convex portion 168 against the abutting portion 164a. Accordingly, the abutting portion 164a can be firmly pressed against the heat sink 130, so that the positioning of the heat sink 130 and the base portion 150 in the distance direction can be performed with higher accuracy.

  In the present embodiment, the abutting portion 164b is located immediately below the contact portion between the screw 172 and the convex portion 168. Therefore, the abutting portion 164b can function as a pedestal for suppressing deformation of the base portion 150 that may occur when the coupling portion 156 is sandwiched between the head portion 172a of the screw 172 and the extension portion 134.

  In the optical unit 100 formed by assembling the reflector 110, the heat sink 130, and the base portion 150 as described above, the light emitted from the light source module 200 is reflected by the reflecting surface 110a of the reflector 110 and attached to the reflector. The light passes through the vicinity of the front end portion 152 b of the portion 152 and enters the projection lens 102. The light incident on the projection lens 102 is collected by the projection lens 102 and is irradiated forward of the vehicle. Thereby, the low beam light distribution pattern can be formed in front of the vehicle.

  As shown in FIGS. 2 and 10, in the optical unit 100 according to this embodiment, the extension part 134 of the heat sink 130 passes below the reflector attachment part 152 and has an optical axis that is longer than the front end part 152 b of the reflector attachment part 152. Extends forward in the direction. The extension part 134 is connected to the connecting part 156 of the base part 150 by the connecting mechanism 170. Here, since the projection lens 102 having a relatively large mass is attached to the front end portion of the base portion 150, the center of gravity is closer to the front of the vehicle. For this reason, in the conventional structure in which the base portion is attached to the heat sink by a fastening screw extending from the back side of the heat sink, the position where the base portion and the heat sink are connected is away from the position of the center of gravity of the base portion. On the other hand, in the optical unit 100 according to the present embodiment, the base unit 150 and the heat sink 130 are coupled at a position closer to the center of gravity of the base unit 150 than in the conventional structure. Therefore, the rigidity of the optical unit 100 with respect to external vibration or the like can be increased as compared with the conventional structure.

  Moreover, in the conventional structure, since the fastening screw was inserted into the heat sink from the back side of the heat sink, it was not possible to dispose the radiating fin in the region through which the fastening screw of the heat sink was inserted. On the other hand, in this embodiment, since the coupling part 156 and the extension part 134 are connected, the number or area of the radiation fins that can be provided on the back surface of the heat sink 130 can be increased as compared with the conventional structure. . Therefore, the heat dissipation of the optical unit 100 can be further improved.

  Further, as described above, the extension part 134 of the heat sink 130 extends forward from the front end part 152 b of the reflector mounting part 152 through the lower part of the reflector mounting part 152. Therefore, compared with the conventional structure in which the radiating fins are provided only on the back side of the heat sink, the radiating fins 135 can be disposed closer to the light source module 200 and the number of radiating fins can be increased. . Therefore, the heat dissipation of the optical unit 100 can be further improved. Alternatively, by providing the heat dissipating fins 135 of the extension part 134, the number or area of the heat dissipating fins 137 on the back surface 136 side can be reduced while ensuring the heat dissipating property of the optical unit 100. The direction dimension can be reduced.

  In the optical unit 100 according to this embodiment, the extension part 134 of the heat sink 130 is exposed in a space surrounded by the lens attachment part 154, the coupling part 156, and the reflector attachment part 152 of the base part 150. In the conventional optical unit, the base part is a substantially horizontal flat part corresponding to the reflector mounting part 152, and the curved part is curved downward so as not to block the incidence of the light source light on the projection lens in front of the flat part. And had a department. In such a conventional optical unit, sunlight incident from the outside through the projection lens is condensed near the curved portion of the base portion, and the resin base portion may be deformed or melted. In order to prevent deformation and melting of the base part, a method of forming the base part with a material having high heat resistance, or escaping the curved part backward in the optical axis direction and moving it away from the sunlight collecting part can be considered. In this case, the manufacturing cost and the size of the optical unit are increased. On the other hand, in the optical unit 100 according to the present embodiment, the extension part 134 that is a part of the heat sink 130 is exposed in a space surrounded by the lens attachment part 154, the coupling part 156, and the reflector attachment part 152. That is, the extension part 134 is disposed in the existing area of the curved part in the conventional structure. Therefore, it is possible to avoid the possibility that the base portion is deformed or melted due to the collection of sunlight without increasing the manufacturing cost and increasing the size.

  In general, the base portion is subjected to a vapor deposition process such as silver in order to increase the light utilization factor of the light source module, thereby increasing the light reflectance. Therefore, in the conventional structure, there is a possibility that the light of the light source module that is externally reflected on the incident surface of the projection lens is reflected by the curved portion of the shade, enters the projection lens, and is irradiated from the projection lens to the front of the vehicle. . The light reflected by the curved portion and applied to the front of the vehicle may be out of the irradiation range of the light distribution pattern to be formed, which may cause glare to other vehicles. On the other hand, in the present embodiment, since the extension portion 134 having a light reflectance smaller than that of the bending portion is disposed in the existing region of the bending portion in the conventional structure, the possibility of giving glare to other vehicles is reduced. be able to.

  In the present embodiment, the screw hole 174 is provided in the base portion 150, and the screw receiving portion 176 is provided in the heat sink 130. Therefore, it is possible to provide heat radiating fins also on the back side portion of the screw receiving portion 176 in the extension portion 134. Therefore, the heat dissipation of the optical unit 100 can be further improved.

  FIG. 13 is a schematic front view of the optical unit according to the first embodiment. In FIG. 13, the projection lens 102 is not shown. As shown in FIG. 13, in the optical unit 100 according to the present embodiment, the coupling mechanism 170 is provided at a position overlapping the projection lens 102 attached to the lens attachment portion 154 when the optical unit 100 is viewed from the front. Furthermore, in the present embodiment, the central axis of the screw hole 174 is disposed on the inner side in the vehicle width direction than the end of the lens mounting portion 154 (see FIG. 10). Further, the coupling mechanism 170 is disposed outside the region through which light reflected by the reflecting surface 110a of the reflector 110 passes. In this way, the optical unit 100 can be reduced in size by arranging the coupling mechanism 170 in a region that overlaps the projection lens in a front view and that does not affect the formation of the light distribution pattern. Further, in the optical unit 100 according to the present embodiment, the radiation fins 135 provided on the extension part 134 are visible from the outside through the projection lens 102 attached to the lens attachment part 154. Therefore, the appearance of the optical unit 100 can be made novel, and the design of the optical unit 100 can be improved.

  As described above, in the optical unit 100 according to this embodiment, the reflector 110 has the fixing pin 114 on the facing surface 112, and the base portion 150 has the pin hole 158 at a position corresponding to the fixing pin 114. Then, the fixing pin 114 is inserted into the pin hole 158 and the reflector 110 is fixed to the base portion 150. Therefore, compared with the conventional structure which attaches a reflector to a base part by lance engagement, a possibility that the reflector 110 may deform | transform can be reduced. Therefore, the formation accuracy of the light distribution pattern can be increased. Further, the shapes of the reflector 110 and the base portion 150 can be simplified as compared with the conventional structure that engages with the lance, and the outer dimensions of the reflector 110 can be reduced.

  Further, in the optical unit 100 according to the present embodiment, the base portion 150 includes the coupling portion 156 that couples the reflector mounting portion 152 and the lens mounting portion 154, and the heat sink 130 passes below the reflector mounting portion 152 and the reflector mounting portion. An extension 134 extending forward in the optical axis direction from the front end 152b of 152 is provided. Then, the extension part 134 and the coupling part 156 are connected by the connection mechanism 170. Therefore, the connecting position of the base part 150 and the heat sink 130 can be brought closer to the position of the center of gravity of the base part 150 as compared with the conventional structure in which the base part is attached to the heat sink with a fastening screw extending from the back side of the heat sink. Thereby, the rigidity of the optical unit 100 can be increased.

  Further, in the optical unit 100 according to the present embodiment, the extension part 134 of the heat sink 130 is exposed in a space surrounded by the lens attachment part 154, the coupling part 156, and the reflector attachment part 152 of the base part 150. Therefore, it may occur in a conventional structure including a base portion having a flat portion disposed substantially horizontally and a curved portion that is curved downward so as not to block light source light incident on the projection lens in front of the flat portion. Therefore, it is possible to avoid deformation and melting damage of the base portion due to sunlight collection. Further, in the optical unit 100 according to the present embodiment, the extension portion 134 of the heat sink 130 is disposed in the existing region of the curved portion in the conventional structure, thereby avoiding melting of the base portion. Therefore, an increase in manufacturing cost and an increase in size of the optical unit 100 can be avoided as compared with the case where the base portion is formed of a material having high heat resistance and the curved portion is structured to be away from the sunlight condensing portion. .

  The present invention is not limited to the above-described embodiments, and various modifications such as design changes can be added based on the knowledge of those skilled in the art, and the embodiments to which such modifications are added are also described in the present invention. It is included in the scope of the invention. A new embodiment generated by the combination of the above-described embodiment and the following modified example has the effects of the combined embodiment and modified example.

  FIG. 14 is a schematic plan view of the vicinity of the coupling portion of the base portion in the optical unit according to the modification. As shown in FIG. 14, in the optical unit 100 according to the modification, a part of the convex portion 168 extends radially with respect to the center M of the screw hole 174. The other part extends substantially perpendicular to the straight line L. Specifically, of the convex portion 168, the side near the abutting portion 164a extends substantially perpendicular to the straight line L, and the side far from the abutting portion 164a extends radially with respect to the center M. In this modification, a convex portion 168 is provided so that the position of the top in the vehicle front-rear direction is the same as the center M of the screw-through hole 174 or on the rear side of the center M so as to be substantially orthogonal to the straight line L. Also, convex portions 168 located on the vehicle front side are provided radially.

  When the convex portions 168 are arranged radially, the direction in which the force that presses the convex portion 168 by the screw 172 is easily transmitted can be made different in each convex portion 168, and the force that presses the convex portion 168 can be diffused. . Therefore, the amount of transmission of the force that presses the convex portion 168 against the abutting portion 164 can be reduced. On the other hand, since the abutting portion 164b is disposed at the periphery of the screw-through hole 174, there is a possibility that the force pressing the convex portion 168 is excessively transmitted. Therefore, in this modification, the projecting portion 168 closer to the butting portion 164a is disposed substantially perpendicular to the straight line L, so that the butting portion that is separated from the contact portion between the screw 172 and the projecting portion 168 is provided. By increasing the amount of transmission of the force that presses the convex portion 168 to 164a and arranging the convex portions 168 of other portions radially, the convex portion 168 to the abutting portion 164b provided immediately below the contact portion is provided. The transmission amount of the pressing force is reduced. Thereby, it is possible to avoid applying excessive pressing force to the extension part 134 via the abutting part 164b. Therefore, it is possible to avoid the possibility that each part is deformed or damaged when the base part 150 and the heat sink 130 are connected, so that the yield of the optical unit 100 can be improved.

  In the above-described embodiment, the fixing pin 114 is provided on the opposing surface 112 of the reflector 110 and the pin hole 158 is provided on the reflector mounting surface 152a of the base portion 150. However, the fixing pin 114 is provided on the reflector mounting surface 152a. The pin hole 158 may be provided in the opposing surface 112. In the above-described embodiment, the abutting portion 118 is provided on the facing surface 112, but the abutting portion 118 may be provided on the reflector mounting surface 152a. In this case, the abutting portion 118 comes into contact with the facing surface 112, and the reflector 110 and the base portion 150 are positioned in the distance direction. Furthermore, in the above-described embodiment, the abutting portion 164 is provided in the base portion 150, but the abutting portion 164 may be provided in the heat sink 130.

  In the above-described embodiment, the optical unit 100 is for forming a low-beam light distribution pattern, and the front end portion 152b of the reflector mounting portion 152 forms a shade for forming a cut-off line of the low-beam light distribution pattern. The optical unit 100 may be for forming a high beam light distribution pattern or another light distribution pattern.

  In the above-described embodiment, the fixing pin 114 is provided with the large diameter portion 114a to prevent the fixing pin 114 from excessively entering the pin hole 158. However, the fixing pin 114 is prevented from excessively entering the pin hole 158. The structure to be prevented is not particularly limited, and for example, a convex portion that protrudes toward the reflector mounting surface 152a may be provided on the opposing surface 112 around the fixing pin 114. Or you may provide the convex part which protrudes toward the opposing surface 112 on the reflector mounting surface 152a around the pin hole 158. These convex portions have, for example, the same height as the height of the large diameter portion 114a, that is, the distance from the opposing surface 112 to the parallel surface 114b. Further, these convex portions may have a top surface parallel to the opposing reflector mounting surface 152 a or the opposing surface 112. In these cases, when the fixing pin 114 is inserted into the pin hole 158 and the reflector 110 is pressed toward the base portion 150, the convex portion comes into contact with the opposing reflector mounting surface 152 a or the opposing surface 112. Thus, the fixing pin 114 can be prevented from excessively entering the pin hole 158. For example, the above-mentioned convex part is a substantially rectangular shape in plan view, one is arranged on the vehicle front side with respect to the pin hole 158, and the other one is arranged on the vehicle rear side with respect to the pin hole 158. And these two convex parts are arrange | positioned so that the longitudinal direction may become substantially parallel to a vehicle width direction.

  100 optical unit, 110 reflector, 110a reflecting surface, 112 facing surface, 114 fixing pin, 114a large diameter portion, 114b parallel surface, 114c pin head, 118 abutting portion, 150 base portion, 152 reflector mounting portion, 152a reflector mounting Placement surface, 158 pin hole, 200 light source module, H gap.

Claims (5)

An optical unit used in a vehicle lamp,
A heat sink for heat dissipation of the light source;
A projection lens that includes a reflector mounting portion, a lens mounting portion, and a coupling portion between the reflector mounting portion and the lens mounting portion, and the light of the light source is reflected by a reflector that is mounted on the reflector mounting portion and is mounted on the lens mounting portion. A base configured to be incident on the
A coupling mechanism for the heat sink and the base,
The heat sink has an extension that extends below the reflector mounting portion and extends forward in the optical axis direction of the optical unit from the front end of the reflector mounting portion.
The optical unit is characterized in that the connection mechanism connects the coupling portion and the extension portion.   The optical unit according to claim 1, wherein the coupling mechanism is provided at a position overlapping with a projection lens attached to the lens attachment portion when the optical unit is viewed from the front. The coupling mechanism includes a screw having a head, a screw through hole provided in the coupling portion, and a screw receiving portion provided in the extension portion,
The optical unit according to claim 1 or 2, wherein the screw is inserted into the screw through hole and screwed into the screw receiving portion, and the coupling portion is sandwiched between the head portion and the extension portion. The coupling portion has a plurality of convex portions that are crushed in contact with the head portion around a screw hole,
At least one of the base part and the heat sink has a plurality of abutting parts in contact with the other,
The optical unit according to claim 3, wherein at least a part of the convex portion extends substantially perpendicular to a straight line passing through a center of the screw hole and a center of the abutting portion. The abutting portion is disposed on the periphery of the screw through hole,
The optical unit according to claim 4, wherein a part of the convex portion extends radially with respect to the center of the screw hole.

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